Nonwoven with non-symmetrical bonding configuration

ABSTRACT

A nonwoven has low tensile and high elongation in the first direction (typically the CD) and high tensile and low elongation in the second direction (typically the MD). The nonwoven has a plurality of bonding points defining a total bonding area along the second direction greater than along the first direction. Accordingly, the nonwoven has unbonded fiber portions and bonded fiber portions, with a bonded portion/unbonded portion ratio greater along the second direction than along the first direction. The bonding points are preferably either circular or oval in plan.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of U.S. patent application Ser. No.09/374,825, filed Aug. 13, 1999, now abandoned.

BACKGROUND OF THE INVENTION

The present invention relates to a nonwoven having a non-symmetricalbonding configuration yielding low tensile strength and high percentelongation in a first direction (e.g., CD) and high tensile strength andlow percent elongation in a second direction (e.g., MD).

Spunbond nonwoven fabrics are made of continuous strands or filamentsthat are laid down on a moving conveyor belt in a randomizeddistribution. In a typical spunbond process, resin pellets are processedunder heat to a melt and then fed through a spinnerette to createhundreds of thin filaments or threads. Jets of air cause the threads tobe elongated, and the threads are then blown onto a moving web wherethey are laid down and sucked against the web in a random pattern tocreate a fabric. The fabric then passes through a bonding station.Bonding is necessary because the filaments or threads are not woventogether.

The typical bonding station includes a bonding roll defining a series ofidentical raised points (bonding points). These bonding points aregenerally equidistant from each other and are in a uniform symmetricalpattern extending in both the machine direction (MD) and the crossdirection (CD).

Other nonwoven fabrics include fabrics made from staple fibers,meltblown fibers, carded fibers and short cut fibers. As used herein theterms “spun fibers” and “fibers” include the spun filaments describedabove as well as staple fibers, meltblown fibers, carded fibers andshort cut fibers.

A non-symmetrical bonding pattern could result in a fabric with anexpected or standard elongation in one direction (e.g., MD), butincreased elongation in the other direction (e.g., CD). This is adesired attribute in situations where minimal elongation is required inthe machine direction and yet high elongation is required in the crossdirection. For example, any elongation in the machine direction willdisrupt the converting machines that are used to make diapers, whilesubstantial elongation in the cross direction is desired to give eachindividual diaper some give around the wearer's waist.

Accordingly, it is an object of the present invention to provide anonwoven having a non-symmetrical bonding configuration.

Another object of the present invention is to provide a nonwoven fabricwhich is highly extensible in a first direction (typically the CD) ascompared to a second direction (typically the MD).

Another object is to provide such a nonwoven having low tensile strengthand high percent elongation in the first direction (typically the CD),and high tensile strength and low percent elongation in the seconddirection (typically the MD).

It is also an object of the present invention to provide such a nonwovenwhich is simple and economical to manufacture, use and maintain.

SUMMARY OF THE INVENTION

It has now been found that the above and related objects of the presentinvention are obtained in a nonwoven having high elongation in a firstdirection (typically the CD) and low elongation in a second direction(typically the MD). The nonwoven has a plurality of bonding pointsdefining a total bonding area along the second direction greater thanalong the first direction.

In a preferred embodiment, the total bonding area along the seconddirection is 1.1-5.0 times greater than along the first direction. Thenonwoven has unbonded fiber portions and bonded fiber portions, with abonded portion/unbonded portion ratio greater along the second directionthan along the first direction. The first and second directions aremutually transverse, with the first direction preferably being thecross-direction (CD) and the second direction preferably being themachine direction (MD).

Where the bonding points are substantially circular, square or diamondshaped in plan, each of the bonding points are disposed closer to eachother in the second direction than in the first direction. The bondingpoints define gaps of unbonded nonwoven between adjacent bonding pointsin the first direction of a length 1.1-3.0 times greater than the gapsof unbonded nonwoven between adjacent bonding points in the seconddirection.

Where the bonding points are substantially oval or rectangular in plan,each of the bonding points is elongated, extends at an angle less than45 degrees relative to the second direction, and has an extension alongthe second direction 1.1-10.0 times greater than along the firstdirection. The bonding points define gaps of unbonded nonwoven betweenadjacent oval bonding points in the first direction of a length 1.0-3.0times the length of the gaps of unbonded nonwoven between adjacentbonding points in the second direction.

The nonwoven is defined by substantially randomly oriented fibers, andis preferably a spunbond. The bonding points are produced by using anengraved roll to form bonding points on the nonwoven.

BRIEF DESCRIPTION OF THE DRAWING

The above and related objects, features and advantages of the presentinvention will be more fully understood by reference to the followingdetailed description of the presently preferred, albeit illustrative,embodiments of the present invention when taken in conjunction with theaccompanying drawing wherein:

FIG. 1 is a fragmentary schematic top plan view of a nonwoven accordingto the present invention wherein the bonding points are substantiallycircular in plan;

FIG. 2 is a fragmentary schematic top plan view of a nonwoven accordingto the present invention wherein the bonding points are substantiallyoval in plan;

FIG. 2A is a schematic top plan view, to a greatly enlarged scale, of anoval bonding point of FIG. 2; and

FIG. 3 is fragmentary schematic top plan view of an alternative patternof bonding points on a nonwoven according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawing, and in particular to FIGS. 1 and 2thereof, therein illustrated is a nonwoven according to the presentinvention, generally designated by the reference numeral 10. While thenonwoven 10 is preferably a spunbond fabric, it could be a meltblownfabric, a carded nonwoven fabric or any other type of nonwoven. In anycase, the nonwoven 10 is defined by substantially randomly oriented spunfibers.

The nonwoven 10 has a low tensile strength and high percent elongationin a first direction 12 (illustrated by a double-headed arrow as thecross direction or CD) and a high tensile strength and low percentelongation in a second direction 14 (illustrated by a double-headedarrow as the machine direction or MD). The first and second directionsare preferably mutually transverse (that is, they extend at right anglesto one another), optimally with the first direction 12 being the crossdirection (CD) and the second direction 14 being the machine direction(MD). Such a nonwoven is particularly desirable in the diaper-makingindustry where minimal elongation is required in the MD and yet highelongation is required in the CD. These properties facilitatemanufacture of the diaper while providing comfort to the wearer aboutthe waist. As will be appreciated by those skilled in the art,elongation of the nonwoven occurs intermediate the bonding points (andnot at the bonding points).

The nonwoven 10 has a plurality of bonding points 20 defining a totalbonding area along the MD 14 greater than along the CD 12. Moreparticularly, the total bonding area along the MD 14 is preferably1.1-5.0 times greater than along the CD 12.

The disposition of the bonding points 20 closer to each other in the MD14 than in the CD 12 has the effect of increasing the tensile strengthand decreasing the percent elongation of the fabric in the MD 14,relative to the tensile and elongation in the CD 12, thus allowing thefabric elongation along the CD 12 to exceed the fabric elongation alongthe MD 14.

The total bonding ratio may be calculated as follows: (a) Form animaginary rectangle having a long dimension and a short dimension, thelong dimension being aligned with and extending fully across the CD ofthe fabric. (b) Calculate the total bonding area formed by the bondingpoints within the rectangle. (This gives the bonding area along the CD.)(c) Re-orient the rectangle by 90 degrees so that the long dimensionthereof is now aligned with the MD of the fabric. (d) Calculate thetotal bonding area formed by the bonding points within the rectangle.(This gives the bonding area along the MD.) These two bonding areameasurements may then be used to calculate the ratio of the bondingareas in the CD and MD. Note that the long dimension of the rectanglemust exceed the short dimension of the rectangle and is preferably twicethe short dimension.

The bonding points 20 are preferably either substantially circular (asillustrated in FIG. 1 by points 22) or substantially oval (asillustrated in FIG. 2 by points 24) in plan, although other shapes maybe used.

Referring now to FIG. 1 in particular, in nonwoven 10A the circularbonding points 22 are disposed closer to each other in the MD 14 than inthe CD 12. In other words, the center-to-center spacing of the circularbonding points 22 is greater in CD 12 (see ΔCD) than in the MD 14 (seeΔMD). The disposition of the bonding points 22 closer to each other inthe MD 14 than in the CD 12 has the effect of increasing the tensilestrength and decreasing the percentage elongation in the MD 14, relativeto the tensile and elongation in the CD 12, thus allowing the elongationof the nonwoven fabric along the CD 12 to exceed the elongation of thenonwoven fabric along the MD 14.

Adjacent circular bonding points 22 define gaps 30A therebetween alongthe CD 12 having a length 1.1-3.0 times the length of the gaps 30Bdefined by the adjacent circular bonding points 22 in the MD 14. Themagnitude of the gaps increases the elongation properties of thenonwoven 10, thus allowing the elongation along the CD 12 to exceed theelongation along the MD 14.

In a preferred embodiment, the circular bonding points 22 have adiameter of about 0.3-1.0 mm and a center-to-center separation of about2 times the diameter in the CD and 1.5 times the diameter in the MD.

A particularly simple yet effective distribution of circular bondingpoints 22 involves the theoretical formation of a uniform pattern (thatis, the center-to-center spacing of the circular bonding points 22 beinguniform in both the MD and CD), and then removal of alternate lanes ofthe circular bonding points 22 extending in the MD, thereby to increasethe relative center-to-center spacing in the CD, so that the finalfabric has a greater percent elongation in the CD than in the MD. Thesame technique can be used with square or diamond shaped bonding points.

Referring now to FIGS. 2 and 2A in particular, in nonwoven 10B the ovalbonding points 24 have an extension MDE along the MD 14 which ispreferably 1.1-10.0 times greater than the extension CDE along the CD12. Where the extension MDE along the MD 14 exceeds the extension CDEalong the CD 12, the resulting fabric has a higher tensile strength anda lower percentage elongation in the MD 14, relative to the tensile andelongation in the CD 12, thus allowing the elongation of the fabricalong the CD 12 to exceed the elongation of the fabric along the MD 14.The oval bonding points are elongated and preferably extend at an angleof less than 45 degrees relative to the MD 14. The oval bonding pointsmay be disposed closer to each other in the MD 14 than in the CD 12,thus also allowing the elongation along the CD 12 to exceed theelongation along the MD 14.

The oval bonding point 24 is preferably annular in design, with thecentral portion defining a plateau, and defines a bonded oval (includingthe annulus thereof) having a preferred length or major dimension ofabout 0.0347 in. (0.882 mm) and a preferred width or minor dimension ofabout 0.02 in. (0.526 mm). The center of an oval bonding point 24 isconsidered herein to be the intersection of its major and minor axes.The separation between the centers of adjacent oval bonding points 24 inthe MD 14 (ΔMD) is preferably about 0.0598 in. (1.521 mm), and theseparation between the centers of adjacent oval bonding points 24 in theCD 12 (ΔCD) is preferably about 3.5 mm.

Adjacent oval bonding points 24 define gaps 30A of unbonded nonwovenfabric therebetween along the CD 12 greater in length than the gaps 30Bof unbonded nonwoven fabric defined by the adjacent oval bonding points24 along the MD 14. The magnitude of the gaps of unbonded nonwovenfabric increases the elongation property of nonwoven 10, thus allowingthe nonwoven elongation along the CD 12 to exceed the nonwovenelongation along the MD 14. Rectangular shaped bonding points could beused in place of oval shaped points.

Viewing the nonwoven 10 according to the present invention from adifferent perspective, the nonwoven 10 has unbonded fiber portions 30characterized by the absence of bonding points 20 and bonded fiberportion 32 characterized by the presence of bonding points 20. Thebonded portion 32/unbonded portion 30 ratio (in terms of surface area)is greater along the MD 14 than along the CD 12. The nonwoven of thepresent invention retains the expected softness, bulkiness, fiber tiedown, abrasion resistance, bond strength and overall bonding area asprior art nonwovens.

The bonding points 20 are preferably produced by a thermobonding processusing an engraved roll (not shown) to form bonding points 20 on thenonwoven. Spunbond nonwovens typically involve the use of thermofusion,chemical or mechanical bonding techniques to secure the spun fiberstogether, and the present invention is applicable to all suchtechniques. For example, in one bonding technique the fabric is passedbetween a smooth heated roller and an engraved roll which includes therequired bonding point shape and/or pattern. In another bondingtechnique, the fabric is passed between an ultrasonic welding apparatusand the engraved roll. In another method adhesive is used to bind thespun fibers together at the bonding points. Circular or oval bondingpoints 22 or 24 are preferred to polygonal bonding points. Further, eachbonding point could be a collection of smaller bonding points that aregrouped together.

FIG. 3 schematically illustrates alternative nonwoven 10C according tothe present invention. Clearly, square or polygonal (rectangular,hexagonal, etc.) bonding points may be used instead of oval or circularones.

FIG. 3 shows a nonwoven 10C with a pattern using oval bonding points 24,which is a variant of that illustrated in FIG. 2. The oval bondingpoints 24 define gaps in the nonwoven between adjacent oval bondingpoints 24 in the CD 12 of a length 1.1-3.0 times the gaps definedbetween adjacent oval bonding points 24 in the MD 14.

In each of the patterns illustrated herein, the nonwoven has a pluralityof bonding points defining a total bonding area along the MD greaterthan along the CD, so that the nonwoven exhibits low tensile and highelongation in the MD and high tensile and low elongation in the CD.

The nonwovens 10A-10C typically fall into one of two categories ofnon-symmetrical bonding pattern configurations. FIG. 1A with itscircular bonding points 22 falls into the first category wherein thebonding point shapes are uniform in both the MD and CD (for each bondingpoint), but the pattern of the bonding points is non-uniform (here,because the ΔCD exceeds the ΔMD). Other uniform bonding point shapesinclude squares or diamonds. On the other hand, FIGS. 2 and 3 with theiroval bonding points 24 fall into the second category wherein the bondingpoint shapes are non-uniform in the MD and CD (because the extension MDEin the MD 14 exceeds the extension CDE in the CD 12), and the pattern ofthe bonding points may be uniform or not. FIG. 2, with its oval points24, falls in the second category. In FIGS. 2 and 3 the bonding patternis non-uniform in the MD and CD which contributes to an increasedelongation in the CD. In a uniform bonding pattern, the distance betweenbonding points in the machine direction (ΔMD) and the distance betweenbonding points in the cross direction (ΔCD) would be equal.

Utilizing a uniform diamond bonding point shape with a non-uniformbonding point pattern, specifically, a center-to-center separation ofbonding points in the CD that is approximately 3.5 times greater thanthe center-to-center separation of bonding points in the MD, nonwovenfabrics of various weights (gsm or grams per square meter) were preparedand two inch wide by five inch long samples were tested for bothelongation and tensile strength utilizing the EDANA test method ERT20.2-89. The tests yielded the following results:

Basis Weight 10 gsm 15 gsm 20 gsm MD tensile N 18.19 20.25 27.95 MDelongation % 75.83 70.40 71.66 CD tensile N  8.50 11.48 16.07 CDelongation % 88.75 92.51 94.67

To enhance longevity of the engraving roll an overlapping pattern in theCD direction is preferred so that the engraving roll is always incontact with the nonwoven being bonded.

As used herein, “elongation” refers to the percentage elongation of aspecimen at the breakpoint, and “tensile” refers to the ultimate tensilestrength of a specimen at the breakpoint.

As will be appreciated by those skilled in the art, in order to effectchanges in both the MD and CD properties, variations in the preliminarycompositions, bonding parameters, and thermodynamic parameters (e.g.,the drawing, cooling and quenching parameters) may be used. Suchparameter changes affect both the MD and CD properties. By way ofcontrast, only a non-symmetrical bonding pattern minimizes theproperties in one direction, while maximizing the properties in theother direction.

While the embodiments described hereinabove utilize bonding points 20which are circular 22, oval 24 or rectangular 24′, it will beappreciated that a wide variety of shapes and configurations may be usedfor the bonding points 20. Indeed, bonding points of different shapesand configurations may be used on a single fabric. Similarly, while avariety of non- symmetrical bonding configurations have been shown inthe various embodiments, it will be appreciated that othernon-symmetrical configurations may be used instead. The criticallimitation is that the shaping and configuration of the bonding pointsand/or the particular bonding pattern create a fabric which meets thegoal of the present invention—namely, a high percent elongation in thefirst direction (typically the CD) relative to a low percent elongationin the second direction (typically the MD).

The nonwoven fabric of the present invention is preferably formed by theselective bonding of substantially randomly oriented fibers initiallyproviding a uniform fiber density in both the MD and CD so that anydistinction between the MD and the CD properties arises out of theselective bonding process of the present invention. However, theselective bonding process of the present invention may also be appliedto a nonwoven fabric which does not have a uniform fiber density in boththe MD and the CD. See the inventor's copending U.S. patent applicationSer. No. 09/373,826, filed Aug. 13, 1999 entitled “Nonwoven Fabric WithHigh CD Elongation And Method Of Making Same”). Where the non-uniformfiber density of the initial nonwoven fabric promotes a greater percentelongation in the CD than the MD, the use of the selective bondingpattern merely enhances the elongation ratio (that is, increases theratio of elongation in the CD to elongation in the MD). Where thenon-uniform density of the initial nonwoven fabric promotes a greaterpercent elongation in the MD than in the CD, the selective bonding ofthe present invention must be effective to overcome the initial bias andstill cause the fabric to have a greater percent elongation in the CDthan in the MD.

A preferred embodiment of the present invention provides a method ofmaking a nonwoven fabric from spun fibers wherein the density of thebonding of the spun fibers in the fabric varies between strips ofrelatively high bonding density and strips of relatively low bondingdensity, the strips extending along the length of the fabric in themachine direction in an alternating pattern, with the high densitystrips separated from each other by low density strips. The alternatinghigh density and low density strips across the cross direction providesthe fabric with a higher percent elongation in the cross direction thanin the machine direction.

An unexpected attribute of the fabric is an increased bulk densityresulting in enhanced softness compared to symmetrically bondednonwovens. In one example, a symmetrically bonded 15 gsm polypropylenespunbond fabric had one-half the thickness compared to a 15 gsmpolypropylene spunbond fabric when bonded with the symmetrical patterndescribed herein.

The materials of the present invention find utility in a wide variety ofindustrial applications. For example, the materials are useful asfilters for air filtration, car filters, liquid filters and filter bags.The materials are also useful in industrial protective clothing such asclean room apparel, commodity consumer clothing, dust protection andchemical protection. The materials are further useful as industrialwipes such as clean room wipes, oil absorption wipes, lens cleaningwipes, and surface protection for low friction and/or non- scratchsurfaces. Other industrial applications for the materials include housewrapping, packaging, furniture and bedding, car covers, insulation,battery separators, shoe components and the like.

Further, the materials of the present invention find utility in a widevariety of hygiene applications. For example, the materials are usefulas topsheets, backsheets or outer covers, leg cuffs, waistbands, stretchtabs, elastic or extendable side panels, and acquisition or distributionlayers.

Finally, the materials of the present invention also find utility in awide variety of medical applications. For example, the materials areuseful as surgical drapes, surgical gowns, cut-in-place gowns, shoecovers, bouffant caps and sterilization wrapping.

The specification of particular applications hereinabove is to be takenas exemplary only, and not as limiting. Uses other than the aforenotedindustrial, hygiene and medical applications follow naturally from thephysical and chemical properties of the materials of the presentinvention.

The asymmetric bonding pattern materials of the present invention findparticular utility in hygienic applications, especially as topsheets,backsheets or outer covers, stretch tabs, elastic or extendable sidepanels and acquisition or distribution layers.

To summarize, the present invention provides a nonwoven having anon-symmetrical bonding pattern and, in particular, a low tensile andhigh elongation in the first direction (typically the CD) and hightensile and low elongation in the second direction (typically the MD).The nonwoven is suitable for use in the diaper-making industry, and issimple and economic to manufacture, use and maintain.

Now that the preferred embodiments of the present invention have beenshown and described in detail, various modifications and improvementsthereon will become readily apparent to those skilled in the art.Accordingly, the spirit and scope of the present invention is to beconstrued broadly and limited only by the appended claims, and not bythe foregoing specification.

We claim:
 1. A nonwoven formed into a fabric having high elongation in afirst direction and low elongation relative thereto in a seconddirection, said nonwoven consisting essentially of substantiallyrandomly oriented, substantially continuous fibers, said nonwoven havinga regular pattern of bonding points, said points having a commonorientation and common dimensions and defining a total bonding areaalong said second direction greater than along said first direction,said points forming a uniform pattern of bond density in the firstdirection different from a uniform pattern of bond density in the seconddirection.
 2. The nonwoven of claim 1 wherein said total bonding areaalong said second direction is 1.5-5.0 times greater than along saidfirst direction.
 3. The nonwoven of claim 1 wherein said nonwoven has alow tensile strength in the first direction and a high tensile strengthrelative thereto in the second direction.
 4. The nonwoven of claim 1wherein said bonding points are substantially oval in plan.
 5. Thenonwoven of claim 4 wherein each of said oval bonding points has anextension along said second direction 1.1-10.0 times greater than alongsaid first direction.
 6. The nonwoven of claim 4 wherein said ovalbonding points are elongated and extend at an angle less than 45°relative to said second direction.
 7. The nonwoven of claim 4 whereinsaid oval bonding points define gaps therebetween of unbonded nonwovenin said first direction of a length 1.1-3.0 times the length of the gapstherebetween of unbonded nonwoven defined by said oval bonding points insaid second direction.
 8. The nonwoven of claim 1 wherein said bondingpoints are circular in plan and disposed closer to each other in saidsecond direction than in said first direction.
 9. The nonwoven of claim8 wherein said circular bonding points define gaps therebetween ofunbonded nonwoven in said first direction of a length 1.1-3.0 times thegaps therebetween of unbonded nonwoven defined by said circular bondingpoints in said second direction.
 10. The nonwoven of claim 1 whereinsaid first and second directions are mutually transverse.
 11. Thenonwoven of claim 10 wherein said first direction is the cross-direction(CD) and said second direction is the machine direction (MD).
 12. Thenonwoven of claim 1 wherein said nonwoven is selected from the groupconsisting of a spunbond fabric and a meltblown fabric.
 13. The nonwovenof claim 1 wherein said bonding points are produced by a processselected from the group consisting of a thermobonding process using anengraved roll to form bonding points on said nonwoven, an ultrasonicprocess using an engraved roll using an engraved roll to form bondingpoints on said nonwoven, and a chemical adhesive process using a screento form bonding points on said nonwoven.
 14. A nonwoven formed into afabric having low tensile strength and high percent elongation in afirst direction and high tensile strength and low percent elongationrelative thereto in a second direction, said nonwoven consistingessentially of substantially randomly oriented, substantially continuousfibers; said nonwoven having a regular pattern of bonding points, saidpoints having a common orientation and common dimensions and defining atotal bonding area along said second direction greater than along saidfirst direction, said total bonding area along said second directionbeing 1.1-5.0 times greater than along said first direction, said pointsforming a uniform pattern of bond density in the first directiondifferent from a uniform pattern of bond density in the seconddirection; said nonwoven having unbonded fiber portions and bonded fiberportions, with a bonded portion/unbonded portion ratio greater alongsaid second direction than along said first direction.
 15. The nonwovenof claim 14 wherein each of said bonding points is substantially oval inplan, has an extension along said second direction 1.1-10.0 timesgreater than along said first direction, and are elongated and extend atan angle less than 45 degrees relative to said second direction, saidoval bonding points defining gaps therebetween of unbonded nonwoven insaid first direction of a length 1.0-3.0 times the gaps therebetween ofunbonded nonwoven defined by said bonding points in said seconddirection.
 16. The nonwoven of claim 14 wherein each of said bondingpoints is circular in plan and disposed closer to each other in saidsecond direction than in said first direction, said circular bondingpoints defining gaps of unbonded nonwoven in said first direction of alength 1.1-3.0 times the gaps of unbonded nonwoven defined by saidcircular bonding points in said second direction.
 17. The nonwoven ofclaim 14 wherein said first and second directions are mutuallytransverse, and said nonwoven is a spunbond defined by substantiallyrandomly oriented fibers, with said bonding points being produced by athermobonding process using an engraving roll to form bonding points onsaid nonwoven.
 18. A nonwoven formed into a fabric having low tensilestrength and high elongation in a first direction and high tensilestrength and low elongation relative thereto in a second direction, saidnonwoven consisting essentially of substantially randomly oriented,substantially continuous fibers, said nonwoven having a regular patternof bonding points, said points having a common orientation and commondimensions and defining a total bonding area along said second directiongreater than along said first direction, said points forming a uniformpattern of bond density in the first direction different from a uniformpattern of bond density in the second direction, said points defininggaps therebetween of unbonded nonwoven in said first direction of alength greater than the length of the gaps therebetween of unbondednonwoven defined by said points in said second direction.
 19. A nonwovenformed into a fabric having high elongation in a first direction and lowelongation relative thereto in a second direction, said nonwovenconsisting essentially of substantially randomly oriented, substantiallycontinuous fibers, said nonwoven having a regular pattern of bondingpoints, said points having a common orientation and common dimensionsand having a center-to-center separation greater in the first directionthan in the second direction, said points forming a uniform pattern ofbond density in the first direction different from a uniform pattern ofbond density in the second direction.
 20. The nonwoven of claim 19wherein bonding points have a shape in plan selected from the groupconsisting of circular, square, oval and diamond.
 21. The nonwoven ofclaim 19 wherein each of the bonding points is formed from a collectionof smaller bonding points that are grouped together.
 22. A nonwovenformed into a fabric having low tensile strength and high elongation inthe CD and high tensile strength and low elongation relative thereto inthe MD, said nonwoven consisting essentially of substantially randomlyoriented, substantially continuous fibers, said nonwoven having aregular pattern of bonding points, said points having a commonorientation and common dimensions and being non-symmetrical in plan,said points forming a uniform pattern of bond density in the CDdifferent from a uniform pattern of bond density in the MD, each bondingpoint having an extension in the CD less than the extension in the MD.23. The nonwoven of claim 22 wherein the bonding points have acenter-to-center separation greater in the CD than in the MD.